sigma lean execution plan for black belts august 11, 2003 discussion document

Sigma Lean Execution Plan for Black BeltsSigma Lean Execution Plan for Black Belts

August 11, 2003

Discussion Document

2© 2003 Six Sigma Academy

Six Sigma Academy Breakthrough Strategy


• Lean- Major portion of knowledge transfer occurs through “apprenticeship” relationship

between Lean Master and Black Belt established from “On-site Lean Events"- Class room workshop augments knowledge transfer approach from Lean Events

• Six Sigma- A great deal of knowledge transfer occurs in class room- Project execution by Black Belt reinforces concepts practiced in class- Master Black Belt mentoring accelerates the speed of project execution by Black Belt

• Change Management - Change management tools are embedded within Six Sigma and/or Lean class room

knowledge transfer

• SigmaLean - Combination of Lean, Six Sigma and Change Management implementation

approaches- Solve both Lean and Six Sigma type problems using the 12 step problem solving

frame work- Apply Lean thinking to Six Sigma approach and Six Sigma thinking to Lean approach

Knowledge Transfer Philosophy for Black Belts


• Assessment and Project Identification- Identify projects for SigmaLean Black Belts- Projects will range from “end-to-end process” problems (traditionally solved by Lean

tools) to tough narrowly scoped variation reduction problems (usually solved with the help of statistically based Six Sigma tools)

• Fastart Session- Each SigmaLean Black Belt will come to the class with two projects – one primary

project and one secondary project- During the Fastart session, the project is scoped with the help of Six Sigma Academy

Master Black Belt- Fastart session will serve as an orientation session and to introduce software used in

the class (Minitab and SigmaFlow)

• Week1 Black Belt Workshop- The 12 step methodology introduced to solve any SigmaLean problem

• Project Execution for Three Weeks- Black Belt starts applying classroom learning from Week1 to his/her project- Mentoring support by Master Black Belt instructor

SigmaLean Deployment Flow


• Week2 Black Belt Workshop- Class room workshop on Lean, Six Sigma and Change Management topics

• Project Execution for Three Weeks- Black Belt continues application of learning from Week2 to his/her project- Mentoring support by Master Black Belt instructor- Additional support from Lean Master to analyze “end-to-end” process problems


• Project Execution for Three Weeks- Black Belt continues application of learning from Week3 to his/her project- Mentoring support by Master Black Belt instructor- Additional support from Lean Master to analyze “end-to-end” process problems- Prepare for lean implementation- Site leadership engaged

SigmaLean Deployment



• Project Execution for Three Weeks- Black Belt continues application of learning from Week4 to his/her project- Mentoring support by Master Black Belt instructor- Lean implementation with active support from Lean Master and site leadership- Report out to site leadership


• Project Execution and Wrap-up- Black Belt continues application of learning from Week5 to his/her project- Mentoring support by Master Black Belt instructor- Additional support from Lean Master to ensure controls are in place on lean

implementations

SigmaLean Deployment


SigmaLean Sample Curriculum

Week 1 WorkshopWeek 1 WorkshopIntroduction and AgendaIntroduction and AgendaIntro to Lean and Lean ThinkingIntro to Lean and Lean ThinkingIntro to Six Sigma – FundamentalsIntro to Six Sigma – FundamentalsSix Sigma Aacdemy's Breakthrough StrategySix Sigma Aacdemy's Breakthrough StrategyThe 12 Step Breakthrough StrategyThe 12 Step Breakthrough StrategyData TypesData TypesBasic StatisticsBasic StatisticsMetricsMetricsTeam Building, Effective MeetingsTeam Building, Effective MeetingsIntroduction to DefineIntroduction to DefineCustomer ValuesCustomer ValuesProject Selection and DefinitionProject Selection and DefinitionSix Sigma Project ManagementSix Sigma Project ManagementProcess and Value Stream MappingProcess and Value Stream MappingProject Financial ManagementProject Financial ManagementKaizen activity pre-improvement- Credit Card Case Study, Round OneKaizen activity pre-improvement- Credit Card Case Study, Round OnePresentations x @ 15 minutes eachPresentations x @ 15 minutes each

Support Week: Support Week: Scope and Align ProjectsScope and Align Projects


SigmaLean Sample CurriculumWeek 2 WorkshopWeek 2 WorkshopReview of prior weekReview of prior weekValue Stream Mapping & Lead Time Value Stream Mapping & Lead Time Types of Waste Types of Waste Workplace Organization Workplace Organization Tools to make Waste Visible (Including Waste Walk)Tools to make Waste Visible (Including Waste Walk)Standardized Operations Standardized Operations Lean BP Workshop 10 method Toolbox Lean BP Workshop 10 method Toolbox Workshop Report Outs Workshop Report Outs Kaizen activity post-improvement - Credit Card Case Study, Round Two Kaizen activity post-improvement - Credit Card Case Study, Round Two Data CollectionData CollectionGraphical AnalysisGraphical AnalysisIntro to DefineIntro to DefineIntro to MeasureIntro to MeasureCause and Effect ToolsCause and Effect ToolsFMEAFMEAMeasurement Systems AnalysisMeasurement Systems AnalysisProcess CapabilityProcess CapabilityProcess Capability for Non-Normal DataProcess Capability for Non-Normal DataMultiple Variable Studies Multiple Variable Studies Review of Define PhaseReview of Define PhaseReview of Measure PhaseReview of Measure PhaseReview of the 12 Steps Review of the 12 Steps Deliverables due Week 3Deliverables due Week 3

Presentations x @ 15 minutes each Presentations x @ 15 minutes each

Support Week: Support Week: Current State Analysis with Lean MasterCurrent State Analysis with Lean Master



Week 3 WorkshopWeek 3 WorkshopReview of Define/MeasureReview of Define/MeasureIntro to AnalyzeIntro to AnalyzeCentral Limit TheoremCentral Limit TheoremConfidence IntervalsConfidence IntervalsIntro to Hypothesis TestingIntro to Hypothesis TestingHypothesis Testing – MeansHypothesis Testing – MeansHypothesis Testing – VariationHypothesis Testing – VariationHypothesis Testing – ProportionsHypothesis Testing – ProportionsHypothesis Testing – Chi-SquareHypothesis Testing – Chi-SquareAnalysis of Variance (ANOVA)Analysis of Variance (ANOVA)Common AssumptionsCommon AssumptionsCorrelation and Simple RegressionCorrelation and Simple RegressionAnalyze Wrap-upAnalyze Wrap-upPresentations x @ 15 minutes eachPresentations x @ 15 minutes each

Support Week: Support Week: Sigma Lean Project Coaching + Sigma Lean Project Coaching + Current State Analysis with Lean MasterCurrent State Analysis with Lean Master



Week 4 WorkshopWeek 4 WorkshopReview of AnalyzeReview of AnalyzeIntro to ImproveIntro to ImproveIntro to DOEIntro to DOEFull Factorial DOEFull Factorial DOE2K Full Factorial2K Full FactorialFractional; FactorialFractional; FactorialCenter PointsCenter PointsBlockingBlockingPower and Sample Size for DOEPower and Sample Size for DOEMultiple RegressionMultiple RegressionImplementation of ImprovementsImplementation of ImprovementsClassroom DOE exercisesClassroom DOE exercisesWrap-up of ImproveWrap-up of ImprovePresentations x @ 15 minutes eachPresentations x @ 15 minutes each

Support Week: Support Week: Sigma Lean Project Coaching +Sigma Lean Project Coaching + Lean Kaizen Implementation Lean Kaizen Implementation



Week 5 WorkshopWeek 5 WorkshopReview of ImproveReview of ImprovePrinciples of Robust DesignPrinciples of Robust DesignIntro to Response Surface Methods (RSM)Intro to Response Surface Methods (RSM)Central Composite Designs (CCD)Central Composite Designs (CCD)Multiple Response Optimization (MRO)Multiple Response Optimization (MRO)Introduction to ControlIntroduction to ControlSustaining the GainsSustaining the GainsControl PlansControl PlansStandardized WorkStandardized WorkMistake ProofingMistake ProofingIntro to SPCIntro to SPCSPC – VariablesSPC – VariablesSPC – AttributeSPC – AttributeOther Corporate and Quality InitiativesOther Corporate and Quality InitiativesIntro to DFSSIntro to DFSSProject Close OutProject Close OutCourse Wrap-upCourse Wrap-upPresentations x @ 15 minutes eachPresentations x @ 15 minutes eachSupport Week: Support Week: Final State Kaizen Action WorkoutFinal State Kaizen Action Workout


Training

Key Tasks

Executive Summit

Pre-Deployment

Leadership Overviews

Executive/Champion Workshops

Tailor Training Materials

Identify Black Belts

2 3 4 5 7 8 96 10 11 121 13 14Month 15

Wave 1-2 Black Belt Project 1 Project 2 Project 3 Project 4

Wave 3-4 Black Belt

Green Belt

Project 1 Project 2 Project 3 Project 4DeliverResults

Master Black Belt

Week 1

Project 1 Project 2

Wave 5-6 Black Belt Project 1 Project 2 Project 3 Project 4

Prioritized Deployment Plan

Sample Deployment Plan

Breakthrough Diagnostics™

$Project Savings / Benefits Occur

Trademarks and Service MarksSix Sigma is a federally registered trademark of Motorola, Inc.

SigmaFlow is a trademark of Compass Partners, Inc.

MINITAB is a trademark of Minitab, Inc.

VarTran is a trademark of Taylor Enterprises.

The following are trademarks of Six Sigma Academy as of March 2003 (alphabetical):Breakthrough DesignBreakthrough ExecutionBreakthrough LeanBreakthrough Sigma LeanBreakthrough Six SigmaBreakthrough Strategy®

Breakthrough Value ServicesDesign for Six Sigma SoftwareDesign Six Sigma for SoftwareDesign with the Power of Six SigmaESSENTEQFASTARTINTELLEQMETREQSigmaCALC® SSA NavigatorWeaving excellence into the fabric of business.


Six Sigma Academy

www.6-sigma.com

Phone: (480) 515-9501

Fax: (480) 515-9507

8876 E. Pinnacle Peak Road

Suite 100

Scottsdale, AZ 85255

sigma lean execution plan for black belts august 11, 2003 discussion document

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